System and method of producing a composite product

ABSTRACT

A method of producing a composite product is provided. The method includes providing a fluidized bed of metal oxide particles in a fluidized bed reactor, providing a catalyst or catalyst precursor in the fluidized bed reactor, providing a carbon source in the fluidized bed reactor for growing carbon nanotubes, growing carbon nanotubes in a carbon nanotube growth zone of the fluidized bed reactor, and collecting a composite product comprising metal oxide particles and carbon nanotubes.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/308,480, filed Mar. 15, 2016, which is incorporated herein byreference in its entirety.

JOINT RESEARCH AGREEMENT

The presently claimed invention was made by or on behalf of the belowlisted parties to a joint research agreement. The joint researchagreement was in effect on or before the date the claimed invention wasmade, and the claimed invention was made as a result of activitiesundertaken within the scope of the joint research agreement. The partiesto the joint research agreement are 1) Honda Research Institute USA,Inc.; and 2) NanoSynthesis Plus, Ltd.

BACKGROUND

Carbon nanotubes are small tube-shaped structures essentially having acomposition of a graphite sheet in a tubular form. Carbon nanotubesfeature diameters less than 100 nanometers, and large aspect ratios,where the length is much greater than is the diameter. For example, alength of the CNT may be more than 1000 times the diameter.Single-walled carbon nanotubes (SWNT) are increasingly becoming ofinterest for various applications in nanotechnology because of theirunique electronic structures, which gives them exceptional thermal,mechanical, and electrical properties. For example, SWNTs can be used inelectronics, energy devices, medicine, and composite materials in orderto obtain desirable physical and chemical properties. These uses requiremethods for producing significant quantities of SWNTs.

Processes for producing SWNTs include, but are not limited to, physicalmethods (e.g., electrical arc, laser ablation) and chemical methods(e.g., pyrolysis, chemical vapor deposition). Once formed, the SWNTs aresometimes distributed within a matrix material, which modifies thethermal, mechanical, and electrical properties of the matrix material.However, the enhancement of electrical or mechanical properties ofmatrix material by nanotube additives requires very homogeneousdispersion, no agglomeration and fine control over the nanotube/matrixratios. Attempts have been made following the synthesis of nanotubes todisperse the nanotubes in various solvents (e.g. via surfacefunctionalization) followed by mixing of the nanotubes with the matrix(e.g. by ball milling, sonication etc.). However, such attempts havefailed to provide satisfactory dispersion of the nanotubes in the matrixas they lead to the reduction of aspect ratio, damage the nanotubes, andincrease the cost of the processed material.

BRIEF DESCRIPTION

In an aspect, a method of producing a composite product is provided. Themethod includes fluidizing an amount of metal oxide particles within afluidized bed reactor, providing a catalyst or catalyst precursor in thefluidized bed reactor, providing a carbon source to a carbon nanotubegrowth zone of the fluidized bed reactor, growing carbon nanotubes inthe carbon nanotube growth zone, and providing a flow of carrier gas tothe fluidized bed reactor and carrying a composite product comprisingcarbon nanotubes and metal oxide particles through the fluidized bedreactor.

In an aspect, a system for use in producing a composite product isprovided. The system includes a fluidized bed reactor comprising anamount of metal oxide particles contained therein, an outlet, a catalystor catalyst precursor source in fluid communication with the fluidizedbed reactor to provide a flow of catalyst or catalyst precursor in thefluidized bed reactor, and a carrier gas source in fluid communicationwith the fluidized bed reactor to carry a composite product comprisingmetal oxide particles and carbon nanotubes grown in the fluidized bedreactor.

In an aspect, a method of producing a composite product is provided. Themethod includes providing a fluidized bed of metal oxide particles in afluidized bed reactor, providing a catalyst or catalyst precursor in thefluidized bed reactor, providing a carbon source in the fluidized bedreactor for growing carbon nanotubes, growing carbon nanotubes in acarbon nanotube growth zone of the fluidized bed reactor, and collectinga composite product comprising metal oxide particles and carbonnanotubes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an exemplary system that may beused to produce a composite product in an aspect of the disclosure.

FIG. 2 is a thermogravimetric analysis (TGA) for lithium nickelmanganese cobalt oxide heated to 750° C. in air.

FIG. 3 is a TGA for lithium nickel manganese cobalt oxide heated to 750°C. in nitrogen.

FIG. 4 is an x-ray powder diffraction (XRD) spectra for lithium nickelmanganese cobalt oxide (a) as received, (b) after heating to 750° C. inair, and (c) after heating to 750° C. in nitrogen.

FIG. 5 is a portion of a view of the XRD spectra of FIG. 4 enlarged formagnification purposes.

FIG. 6 is a flow diagram illustrating an exemplary series of processsteps that may be used in producing a composite product in an aspect ofthe disclosure.

DETAILED DESCRIPTION

The embodiments described herein relate to a composite product, andsystems and methods for making the composite product. In general, thesystems and methods provide for the in-situ dispersion of carbonnanotubes into a metal oxide matrix material in the course of carbonnanotube growth in a reactor. The reactor may be a fluidized bed reactorcapable of aerosolization or fluidization of the metal oxide matrixmaterial with a fluidization gas flowing from a gas distributor, such asa porous frit, from the bottom of the reactor. One or more injectors maybe provided in the middle of the reactor to supply catalyst and carbonprecursors for growing of the carbon nanotubes. Hence, carbon nanotubesmay be grown in a cloud of fluidized metal oxide matrix material toprovide in-situ mixing and, as a result, improved homogeneity of theresulting composite product containing carbon nanotubes and metal oxidematrix material. The composite product may be used in an electrode. In anon-limiting example, the composite product may be used in a cathode ofa secondary lithium battery.

FIG. 1 is a schematic illustration of an exemplary system 100 that maybe used to produce a composite product 102 comprising carbon nanotubesand metal oxide matrix materials. In the exemplary embodiment, system100 includes a fluidized bed reactor 104 having an amount of metal oxidematrix material contained therein. The matrix material may be any solid,metal oxide particle that is capable of being suspended in a fluidizedbed. An exemplary metal oxide includes, but is not limited to, any metaloxide that may be used in an electrode. In an illustrative example, themetal oxide is a material for use in the cathode of the battery.Non-limiting examples of metal oxides include Ni, Mn, Co, Al, Mg, Ti andany mixture thereof. The metal oxide may be lithiated. In anillustrative example, the metal oxide is lithium nickel manganese cobaltoxide (LiNiMnCoO₂). The metal oxide particles can have a particle sizedefined within a range between about 1 nanometer and about 100 microns.In a non-limiting example, the metal oxide particles have an averageparticle size of about 1 nanometer to about 10 nanometers.

In an illustrative example, the fluidized bed reactor 104 includes areaction chamber 108, and a gas distributor that may comprise a porousfrit 110 coupled to reaction chamber 108 and a gas plenum 112 coupled toporous frit 110. Porous frit 110 includes a plurality of flow apertures114 defined therein such that gas plenum 112 is coupled in fluidcommunication with reaction chamber 108. Gas plenum 112 receives a flowof fluidizing gas from a first gas source 118. The flow of fluidizinggas is routed through plenum 112 and the porous frit 110 to fluidize themetal oxide particles in the reaction chamber 108. The fluidizing gasmay be any gas capable of fluidizing the metal oxide particles to form afluidized bed 109 of metal oxide particles. Exemplary fluidizing gasesinclude, but are not limited to, argon, helium, nitrogen, hydrogen,carbon dioxide, and ammonia.

As shown in FIG. 1, the fluidized bed 104 may include one or more heatsources 119 for heating the reaction chamber 108 to the desired reactiontemperature. For example, the reaction chamber 108 may be heated withthe heat source 119 to a temperature in the range of about 450° C. toabout 1100° C. depending on the catalyst or catalyst precursor and thetype of nanotube desired. In one embodiment, especially to accommodatesensitive cathode materials, the reactor can be operated closer to thelower end of this temperature (e.g. ˜500° C.) and in the presence ofhydrogen in order to avoid converting the cathode material. In analternative embodiment, the reactor can be operated closer to the higherend of the aforementioned temperature range (e.g. ˜750° C. and above)and in the absence of hydrogen). The products obtained from operatingthe reactor whether at the lower or higher temperatures are notnecessarily limited to SWNTs. Typically, single-walled nanotubes (SWNTs)require higher temperatures (>750° C.) while multi-walled nanotubes(MWNTs) can be grown as low as about 450° C. In a non-limiting example,the reactor his heated to a temperature of about 450° C. to about 850°C. As shown in FIGS. 2, 3, 4, and 5, lithium nickel manganese cobaltoxide is thermally stable up to at least 850° C. via TGA (FIG. 2 in airand FIG. 3 in nitrogen) and XRD (FIG. 4 and FIG. 5) measurements.Therefore, such a lithiated mixed metal oxide can be provided in afluidized bed reactor at temperatures suitable for the growth of carbonnanotubes.

Fluidized bed reactor 104 may also include one or more inlets forintroduction of the metal oxide particles, the catalyst or catalystprecursor, a carrier gas 127, and the carbon precursor for the carbonnanotubes. As shown in FIG. 1, an inlet 120 is provided for theintroduction of the metal oxide particles from a metal oxide particlesource 106 into the reaction chamber 108. It is to be understood thatany method or device may be used to introduce the metal oxide particlesinto the reaction chamber 108 via the inlet 120. In a non-limitingexample, the metal oxide particles may be fed into the reaction chamber108 with a screw feeder, belt feeder, vibratory feeder, or a rotary(bulk solid) feeder. In addition, or alternatively, the metal oxideparticles may be conveyed pneumatically into the reaction chamber 108.Non-limiting examples include pressure vessel conveyors, pressurizedscrew conveyor, airlifts, blow-through feeders, and jet feeders. Theconveying gas may the same as or different than the fluidizing gas.Exemplary gases include, but are not limited to, argon, nitrogen,helium, hydrogen, carbon dioxide, and ammonia. It is to be understoodthat the metal oxide particles may be continuously fed into the reactionchamber 108 so that the system operates in a continuous operation of thereaction chamber 108, the metal oxide particles may be introduced in asingle charge for batch operation of the reaction chamber 108, or themetal oxide particles may be intermittently added for semi-batchoperation of the reaction chamber 108.

The carbon nanotubes can be synthesized using carbon precursors, such asone or more carbon-containing gases, one or more hydrocarbon solvents,and mixtures thereof. Examples of carbon-containing precursors includecarbon monoxide, aliphatic hydrocarbons, both saturated and unsaturated,such as methane, ethane, propane, butane, pentane, hexane, ethylene,acetylene and propylene; oxygenated hydrocarbons such as acetone, andmethanol; aromatic hydrocarbons such as benzene, toluene, andnaphthalene; and mixtures of the above, for example carbon monoxide andmethane. In general, the use of acetylene promotes formation ofmulti-walled carbon nanotubes, while CO and methane are preferred feedgases for formation of single-walled carbon nanotubes. Specifically,hydrocarbon solvents may include, but are not limited to, alcohols suchas methanol, ethanol, and isopropanol. The carbon precursor mayoptionally be mixed with a diluent gas such as hydrogen, helium, argon,neon, krypton and xenon or a mixture thereof. As shown in FIG. 1, acarbon precursor may be included in a carrier gas 127 (e.g. via carriergas source 126) and introduced to the reaction chamber 108 via inlet128.

The catalyst or catalyst precursors may include any catalyst or catalystprecursor that may be used in the production of carbon nanotubes. Thecatalyst or catalyst precursor may be one or more of an acetylacetonate,a metallocene, an acetate, a nitrate, a nitride, a sulfate, a sulfide,an oxide, a halide, a chloride, and the like. Illustrative metals foruse as the catalyst include, but are not limited to, iron, nickel,cobalt, molybdenum, or a mixture thereof. Non-limiting examples ofcatalyst precursors include iron(III) acetylacetonate, ferrocene, ironacetate, iron nitrate, iron sulfate, and iron chloride. It is to beunderstood that the catalyst or catalyst precursor source may be a solidpowder, a solid dispersed in a liquid, or dissolved in a solvent. Asshown in FIG. 1, a catalyst or catalyst precursor source 130 may beprovided in communication with the reaction chamber 108 via inlet 132 tointroduce the catalyst or catalyst precursor to a carbon nanotube growthzone 150 of the reaction chamber 108. A pump, solids feeder, syringe, orany other device or method known to one of ordinary skill in the art maybe used to introduce the catalyst or catalyst precursor into the carbonnanotube growth zone 150. It is to be understood that the carbonprecursor may be mixed with the catalyst or catalyst precursor andintroduced with the catalyst or catalyst precursor via inlet 132.

As shown in FIG. 1, a collection vessel 170 is provided for collectingthe composite product of metal oxide particles and carbon nanotubes. Thecomposite product exits the reactor 104 at outlet 175 and is collectedin the vessel 170. The vessel 170 may include a porous filter ormembrane 176 that collects the composite product 102 in the vessel 170,but allows the gases leaving the fluidized bed reactor 104 through theexit 175 to be exhausted from the system via outlet 177. In anon-limiting example, the porous membrane may be a porous quartz frit.However, the present disclosure is not limited to such a collectionvessel 170 and porous filter or membrane 176, as any collection systemmay be used that is capable of separating solid particles from a gasstream. Non-limiting examples include one or more cyclone separators andbag houses.

In a non-limiting example, the metal oxide particles can be providedwith a catalyst or catalyst precursor deposited thereon prior tointroduction of the metal oxide particles in the reaction chamber 108.

In operation, the growth rate of carbon nanotubes and the weightpercentage of carbon nanotubes relative to the metal oxide particles inthe composite product is controlled by the feed rates of the metal oxideparticles, the catalyst or catalyst precursor, and the carbon precursorinto the reaction chamber 108. These feed rates can be tailored toproduce the desired ratio of carbon nanotubes to metal oxide particlesin the composite product to meet the needs of a desired application.

In an illustrative example as shown in FIG. 2, a method of making thecomposite product comprises providing a fluidized bed of a metal oxideparticles (step 200), providing a catalyst or catalyst precursor in thefluidized bed (step 300), introducing a carbon source in the fluidizedbed (step 400), growing carbon nanotubes in the fluidized bed (step500), and collecting the composite product comprising metal oxideparticles and carbon nanotubes (step 600). In a non-limiting example, atleast some of the catalyst or catalyst precursor is deposited on thesurface of the metal oxide particles and the carbon nanotubes are grownon the surface of the metal oxide particles.

EXAMPLE Production of Composite Product

To demonstrate the method of producing a composite product comprisingcarbon nanotubes and metal oxide particles, the following experiment wasconducted.

A quartz tube having a 2 inch diameter was provided as the reactionchamber 108 for the fluidized bed reactor 104 and a tube furnace wasused as the heat source 119. The quartz tube was aligned vertically witha lower end closed with the porous frit 114. Two tubes were provided atthe center of the porous frit 114 for the carrier gas inlet 128 and thecatalyst/catalyst precursor inlet 132. Both inlets 128/132 werepositioned below the section of the reaction chamber 108 heated by theheat source 119. Lithium nickel manganese cobalt oxide particles wereused as the metal oxide particles and were poured onto the porous frit114 to a height of about 10 millimeters. The fluidizing gas, argon, wasthen provided at a rate of about 350 sccm (standard cubic centimetersper minute) through the porous frit 114 at the lower end of the quartztube to fluidize the metal oxide particles. The reactor chamber 108 washeated to a temperature of about 800° C. The carrier gas 127 included amixture of argon (about 850 sccm) and hydrogen (about 300 sccm) and wasprovided to the reaction chamber 108 via inlet 128. The catalystprecursor was a solution of ferrocene (0.4 wt %) and thiophene (0.2 wt%) in ethanol. The ethanol functioned as both a solvent for theferrocene and the carbon source for growing the nanotubes. The catalystprecursor solution was injected at a rate of 6 ml/hr via the inlet 132into the carbon nanotube growth zone 150 where the ferrocene decomposedto iron catalyst particles having a diameter of about one nanometer, andthe ethanol was converted to a carbon source for the growth of singlewalled nanotubes on the iron catalyst particles. The carrier gas 127transported the composite product 102 from the nanotube growth zone 150through the reactor outlet 175 and to the collection vessel 170. Thecomposite product included SWCNTs and lithium nickel manganese cobaltoxide particles and comprised approximately 0.7 wt % SWCNTs.

This written description uses examples to disclose variousimplementations, including the best mode, and also to enable any personskilled in the art to practice the various implementations, includingmaking and using any devices or systems and performing any incorporatedmethods. The patentable scope of the disclosure is defined by theclaims, and may include other examples that occur to those skilled inthe art. Such other examples are intended to be within the scope of theclaims if they have structural elements that do not differ from theliteral language of the claims, or if they include equivalent structuralelements with insubstantial differences from the literal language of theclaims.

What is claimed is:
 1. A method of producing a composite product, saidmethod comprising: fluidizing an amount of metal oxide particles withina fluidized bed reactor; providing a catalyst or catalyst precursor inthe fluidized bed reactor; providing a carbon source to a carbonnanotube growth zone of the fluidized bed reactor; growing carbonnanotubes in the carbon nanotube growth zone; providing a flow ofcarrier gas to the fluidized bed reactor and carrying a compositeproduct comprising the carbon nanotubes and the metal oxide particlesthrough the fluidized bed reactor; and including the composite productin an electrode.
 2. The method in accordance with claim 1, whereincarrying the composite product through the fluidized bed reactorcomprises transporting the composite product towards an outlet definednear a top of the fluidized bed reactor.
 3. The method in accordancewith claim 1, further comprising receiving the composite productdischarged from the outlet of the fluidized bed reactor in a collectionvessel.
 4. The method in accordance with claim 1, further comprising atleast one of continuously or periodically replenishing the metal oxideparticles in the fluidized bed reactor.
 5. The method in accordance withclaim 1, further comprising heating the carbon nanotube growth zone to atemperature greater than about 450° C. to less than about 850° C.
 6. Themethod in accordance with claim 1, wherein providing the catalyst orcatalyst precursor comprises injecting the catalyst or catalystprecursor from a bottom portion of the fluidized bed reactor and intothe nanotube growth zone.
 7. The method in accordance with claim 1,wherein providing the carrier gas comprises discharging a flow of thecarrier gas into the nanotube growth zone and transporting the catalystthrough the nanotube growth zone toward the fluidized bed reactoroutlet.
 8. The method in accordance with claim 1, wherein the fluidizedbed reactor comprises a gas distributor positioned below the nanotubegrowth zone, and fluidizing the metal oxide particles within thefluidized bed reactor comprises feeding a fluidizing gas through the gasdistributor at a rate sufficient to fluidize the metal oxide particleswithin the fluidized bed reactor.
 9. The method in accordance with claim1, wherein the metal oxide particles are mixed metal oxide particles,and the carbon nanotubes are single-wall carbon nanotubes.
 10. Themethod in accordance with claim 1, wherein the metal oxide particles arelithiated mixed metal oxide particles, and the carbon nanotubes aresingle-wall carbon nanotubes.
 11. The method in accordance with claim 1,wherein the fluidized bed reactor is heated to a temperature of greaterthan about 450° C. to less than about 850° C.
 12. The method inaccordance with claim 1, wherein the fluidized bed reactor is heated toa temperature of greater than about 800° C.
 13. A method of producing acomposite product, said method comprising: fluidizing an amount of metaloxide particles within a fluidized bed reactor; providing a catalyst orcatalyst precursor in the fluidized bed reactor; providing a carbonsource to a carbon nanotube growth zone of the fluidized bed reactor;growing carbon nanotubes in the carbon nanotube growth zone; andproviding a flow of carrier gas to the fluidized bed reactor andcarrying a composite product comprising the carbon nanotubes and themetal oxide particles through the fluidized bed reactor, wherein themetal oxide particles are lithium nickel manganese cobalt oxideparticles, and the carbon nanotubes are single-wall carbon nanotubes.14. A method of making a composite product comprising: providing afluidized bed of metal oxide particles in a fluidized bed reactor of asystem; providing a catalyst or catalyst precursor in the fluidized bedreactor; providing a carbon source in the fluidized bed reactor forgrowing carbon nanotubes; growing carbon nanotubes in a carbon nanotubegrowth zone of the fluidized bed reactor; collecting a composite productcomprising metal oxide particles and carbon nanotubes; and removing thecomposite product from the system.
 15. The method in accordance withclaim 14 wherein the fluidized bed reactor includes a top and a bottom,a gas distributor is positioned below the nanotube growth zone near thebottom of the fluidized bed reactor, and the metal oxide particles arefluidized in the fluidized bed reactor by feeding a fluidizing gasthrough the gas distributor at a rate sufficient to fluidize the metaloxide particles within the fluidized bed reactor.
 16. The method inaccordance with claim 14 wherein the catalyst or catalyst precursorcomprises ferrocene.
 17. The method in accordance with claim 14 whereinthe catalyst precursor comprises ferrocene and an alcohol, and whereinthe alcohol is the carbon source for growing carbon nanotubes.
 18. Themethod in accordance with claim 14 wherein providing the catalyst orcatalyst precursor comprises injecting the catalyst or catalystprecursor via an inlet to the fluidized bed reactor, wherein the inletis positioned below the nanotube growth zone and above the gasdistributor.
 19. The method in accordance with claim 14 , furthercomprising providing a carrier gas into the nanotube growth zone fortransporting the carbon nanotubes through the nanotube growth zonetoward an outlet of the fluidized bed.
 20. The method in accordance withclaim 14 , wherein the carrier gas includes the carbon source forgrowing carbon nanotubes.
 21. The method in accordance with claim 14,further comprising receiving the composite product discharged from anoutlet of the fluidized bed reactor in a collection vessel.
 22. Themethod in accordance with claim 14, further comprising heating thecarbon nanotube growth zone to a temperature greater than about 1000° C.23. The method in accordance with claim 14, wherein the metal oxideparticles are mixed metal oxide particles, and the carbon nanotubes aresingle-wall carbon nanotubes.
 24. The method in accordance with claim14, wherein the metal oxide particles are lithiated mixed metal oxideparticles, and the carbon nanotubes are single-wall carbon nanotubes.25. The method in accordance with claim 14, wherein the fluidized bedreactor is heated to a temperature of greater than about 450° C. to lessthan about 850° C.
 26. The method in accordance with claim 14, whereinthe fluidized bed reactor is heated to a temperature of greater thanabout 800° C.
 27. The method of claim 14, wherein the metal oxideparticles have a particle size of between about 1 nm and about 10 nm.28. A method of making a composite product comprising: providing afluidized bed of metal oxide particles in a fluidized bed reactor;providing a catalyst or catalyst precursor in the fluidized bed reactor;providing a carbon source in the fluidized bed reactor for growingcarbon nanotubes; growing carbon nanotubes in a carbon nanotube growthzone of the fluidized bed reactor; and collecting a composite productcomprising metal oxide particles and carbon nanotubes, wherein the metaloxide particles are lithium nickel manganese cobalt oxide particles, andthe carbon nanotubes are single-wall carbon nanotubes.